Timing belt drive. Diesel engines 1.9 l (AVB, AWX, AVF)
- 1 - Top toothed belt cover. To remove, remove the air duct to the front panel. When installing, carefully connect to the center cover of the toothed belt
- 2 - Toothed belt
- 3 - Nut, 20 Nm + 45°
- 4 - Tension roller
- 5 - Bolt, 100 Nm
- 6 - Bolt, 25 Nm
- 7 - Camshaft wheel. Mark Position
- 8 - Hub with gear for Hall sensor
- 9 - Bolt, 10 Nm. Screwed on sealant
- 10 — a cover of a gear belt, back
- 11 - Rubber bushing. Replace if damaged
- 12 - Damper belt tensioner
- 13 - Guide roller
- 14 - Coolant pump
- 15 - Crankshaft toothed belt wheel. The mating surface between the toothed belt wheel and the crankshaft must be free of oil. Installation only possible in one position
- 16 — Bolt*, 120 Nm + 90°. Do not grease
- 17 - Bolt, 15 Nm
- 18 - Bolt, 20 Nm
- 19 — a cover of a gear belt lower
- 20 - Crankshaft wheel (vibration damper). Mounting possible in only one position, holes offset
- 21 — Bolt*, 10 Nm + 90°
- 22 - Cover
- 23 - Central timing belt cover. To remove, remove the top cover of the toothed belt and disconnect the V-belt tensioner
*) Be sure to replace.
Withdrawal
1. Set the front panel to the service position, refer to Section Setting the Front Panel to the Maintenance Position.
2. Remove the oil level indicator (1) from the guide tube.
3. Disconnect the covers and unscrew the nuts lying under them (arrows).
4. Remove the engine top cover.
5. Remove the damper lying under it.
6. Reinsert the oil level indicator as far as it will go.
7. Remove the V-belt, refer to Section Removal and installation of a belt of a drive of auxiliary units.
8. Hold the viscous fan pulley with tool 3212 and unscrew it with an 8mm socket wrench (1) from the holder.
9. Remove the viscous fan and place it in the fan shroud.
10. Remove the generator and remove the fan with a viscous coupling from the casing, refer to Section Removal and installation of the generator.
11. Remove the screws (1) And (2) and remove the V-belt tensioner.
12. Remove the top cover of a gear belt.
13. Remove the screws (3) and remove the cover (2).
14. Set aside the boost pressure control solenoid valve (1).
15. Remove the cover from the crankshaft pulley (vibration damper) and unscrew the pulley.
Warning: To loosen and secure the pulley, hold it with a spanner wrench on the center bolt.
16. Disconnect the center and bottom timing belt covers (arrows on the accompanying illustration).
Caution: The crankshaft may only be turned in the direction of engine rotation, i.e. clockwise. The crankshaft is turned with a key for the central bolt.
17. Turn the crankshaft and set it to the TDC position of the first cylinder. In this case, the gap between the legs (1) on the camshaft sensor rotor must lie against the marking «4Z» (2) on the back cover of the toothed belt.
Warning: In the accompanying illustration, for clarity, the wheel is shown without a toothed belt.
18. Fix the hub with HAZET pin 2588-3.
Warning: A 6 mm mandrel can be used instead of the indicated pin.
19. Fix the crankshaft pulley with HAZET pin 2588-1. To do this, insert a special tool (crankshaft stopper) from the end of the toothed belt wheel into its ring gear.
Caution: Marks on the crankshaft sprocket (2) and fixing tool (1) should be opposite each other. In this case, the stud of the tool must enter the hole in the sealing flange. If such a tool is not available, put a TDC mark on the sealing flange.
20. Turn away bolts of fastening (arrows) so that the camshaft wheel turns in the oblong holes.
21. Insert the socket wrench into the hex hole of the tension roller until it stops and turn the tension roller counterclockwise (the direction of the arrow in the accompanying illustration) so that the tensioner can be fixed with the HAZET 2588-2 locking bar.
Caution: The socket wrench is inserted as far as it will go so that it is not damaged when turning the tensioner.
Warning: The toothed belt tensioner is oil damped and should be pressed evenly without much force.
22. If a used toothed belt is installed, mark the direction of rotation on it with chalk or a felt-tip pen.
23. Turn away a nut of fastening of a tension roller.
24. Remove the bolts (arrows on the accompanying illustration) toothed belt tensioner and remove the tensioner.
25. Remove a gear belt.
Installation (variable valve timing)
1. Check whether the camshaft is secured with the HAZET pin 2588-3 and the crankshaft with the HAZET 2588-1 stopper, and whether the toothed belt tensioner is fixed with the HAZET 2588-2 lock plate.
Warning: Adjustment work on the toothed belt may only be carried out when the engine is cold.
Caution: When turning the crankshaft, it is not allowed to stop when any piston is at TDC. There is a risk of damaging the valves and/or piston crowns. If necessary, turn the crankshaft back 90°.
2. Screw in the bolts by hand.
Warning: The camshaft wheel must rotate and not tip over.
3. Turn the camshaft wheel in its oblong holes until it stops.
4. Put the toothed belt on the camshaft wheel, idler pulley, crankshaft wheel and lastly on the coolant pump wheel.
5. Install the toothed belt tensioner.
Toothed belt tension
1. Turn the eccentric tool HAZET 2587-1 counterclockwise until it stops (A) so that the HAZET 2588-2 locking plate can be removed.
2. Turn the tensioner slowly clockwise (overcoming resistance) so that a drill can be easily inserted between the tension arm and the housing (2) 4.0 mm in diameter. Dimension a = 4.0±1.0 mm.
3. While holding the idler in this position, tighten the idler nut (1) moment 20Nm + 45°.
4. Tighten the bolts (arrows in the illustration) camshaft wheel fastening torque 25Nm.
5. Remove HAZET 2588-3 lock pin and HAZET 2588-1 crankshaft stop.
Caution: The crankshaft may only be rotated in the direction of engine rotation.
6. Rotate the crankshaft 2 turns further clockwise until it stops again at the TDC position of the first cylinder.
7. Check the size again «A» between tensioner arm and tensioner housing. Required value: a = 4.0±1.0 mm.
8. If size «A» is not reached, tighten the tension roller as described below.
9. Hold the idler with the HAZET 2587-1 tool and unscrew the nut (1). After that, by the action of the force of the tensioner, release it so (arrow), to reach the size «A». Required value a = 4.0±1.0 mm.
10. While holding the idler in this position, tighten the nut (1) moment 20Nm + 45°.
Checking the valve timing
1. For inspection, fix the toothed belt wheel again with the HAZET 2588-1 crankshaft stopper. When doing so, keep the following in mind:
- Marks on the wheel (2) and crankshaft stopper (1) should be opposite each other. At the same time, the pin of the crankshaft stopper (arrow) must fit into the opening of the sealing flange.
- The pin of the crankshaft stop during rotation must enter the hole on the sealing flange (arrow on accompanying illustration).
- If the crankshaft has passed the TDC mark of the first cylinder, turn the crankshaft 90°back so that it again stops at the TDC position of the first cylinder when rotating in the desired direction.
Caution: Adjustment by rotating the shaft back to set the stopper is not allowed.
2. Check if the hub is fixed with the HAZET 2588-3 locking bar.
3. Gap between legs (1) on the camshaft sensor rotor must lie against the marking «4Z» (2) on the back cover of the toothed belt.
If the hub is not fixed
1. Turn away bolts of fastening (arrows) camshaft wheels.
2. Place a spanner wrench on the camshaft center bolt and turn the hub so that the HAZET 2588-3 locking bar can enter.
3. Tighten the mounting bolts in this position (arrows) camshaft wheel torque 25Nm.
4. Remove HAZET 2588-3 lock pin and HAZET 2588-1 crankshaft stop.
Caution: The crankshaft may only be turned in the direction of engine rotation, i.e. clockwise.
5. Turn the crankshaft 2 turns in the direction of rotation, i.e. clockwise until the crankshaft is again at TDC position of the first cylinder.
6. Repeat the control of the valve timing.
7. Place the viscous fan in the shroud.
8. Install the generator in place, while to facilitate the installation of the generator, the lock bolt bushings knock out a little back, refer to Section Removal and installation of the generator.
9. Fasten the viscous fan with a new bolt 45Nm.
10. Install the V-belt, refer to Section Removal and installation of a belt of a drive of auxiliary units.
11 Replace the front panel, refer to Section Setting the Front Panel to the Maintenance Position.
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